Construction unit



Get. 24, 1367 T. W. MILLS 3,348,350

CONSTRUCTION UNIT Filed Jan. 8, 1965 2 Sheets-Sheet l I NVENTOR.

Oct. 24, 1967 T. W. MILLS 3,343,35G

CONSTRUCTION UNIT Filed Jan. 8, 1965 2 Sheets-Sheet 3 United States Patent 3,348,350 CONSTRUCTION UNIT Thomas W. Mills, 31 Sweet Bay Road, Portuguese Bend, Calif. 90272 Filed Jan. 8, 1965, Ser. No. 424,381 13 Claims. (Cl. 52-542) This invention lies in the field of building construction and relates particularly to wall construction and to prefabricated units adapted to be combined to produce simple but strong, durable, and highly practical wall assemblies, which may be either vertical walls or roofs. This application is a continuation-in-part of my patent application, Ser. No. 365,597, filed May 7, 1964, and now abandoned.

Briefly stated, the invention consists of a wall construction, or assembly, of pre-fabricated units adapted to be arranged on a sub-adjacent supporting framework in successively overlapped, vertical echelon formation to completely cover the conventional framework and constitute a complete exterior wall. The assembly is so constructed and arranged that it obviates the need for discrete shingling, and at the same time provides a simplified equivalent for sheathing. The various elements in the assembly take the flexure, torsion, shear, and other stresses that normally require the use of discreate purlins or other conventional longitudinally extending members.

The present invention, whether used for side wall or roof construction, makes use of three basic components, a starter panel, an intermediate panel, and a finisher panel, each with appropriate attachments to enable them to cooperate in producing the finished assembly. The starter panel, which is used at the bottom of the assembly, is a thin, narrow, elongate wall panel, preferably of plywood although it may be a synthetic plastic or metal sheet, having a pair of parallel, longitudinal, marginal edges.

A first longitudinal flange is attached to a first longitudinal edge and extends away from one face of the panel, preferably perpendicular thereto. This panel is attached to the framework of spaced beams, usually parallel, in such manner that its axis crosses the axes of the beams, and is generally horizontal with the flange lowermost. The free edge of the flange and the other longitudinal edge of the panel contact the beams so that the panel is located in a plane at an acute angle to the common plane of the beams. A second longitudinal flange is attached to the second longitudinal edge of the panel and extends away from the second face in a direction opposite to the first flange.

The intermediate panel, of which there may be any number depending on the height of a side wall or width of a roof, is a thin, narrow, elongate wall panel having a pair of parallel, longitudinal, marginal edges. Its width is approximately twice that of the starter panel. It also has a pair of oppositely disposed longitudinal flanges arranged in the same way as those of the starter panel. In addition, it has a pair of longitudinal ribs which are located in the vicinity of the longitudinal axis of the panel, and one of them extends in the same direction as each of the flanges. The ribs may be exactly in line with each other or slightly offset, depending on the dimensions of the various parts of the assembly.

This panel is now laid on the starter panel with its inwardly extending rib facewise against the second flange of the starter panel and with its inwardly extending flange resting on the starter panel face just opposite the first flange of the starter panel. The second flange of the starter panel contacts the inner face of the intermediate panel to support it and the two panels are now secured together, preferably with nails. They lie in parallel spaced planes at the same acute angle to the plane of the beams, and the overlapping portions define a closed rectangular box which serves various purposes, as later described. The inner longitudinal margin of the intermediate panel contacts the beams and is secured thereto.

If the extent of the wall or roof is great enough, one or more additional intermediate panels can be secured in substantially the same way. The first intermediate panel presents an upstanding rib and an upstanding flange. The second intermediate panel is now arranged so that its lower half overlies the upper half of the first intermediate panel and a flange and rib extend inwardly. This flange and rib lie immediately adjacent to the first flange and rib and 'are secured thereto. Each succeeding intermediate panel is arranged and secured in the same way.

All of the panels are of predetermined modular dimensions. In the present case the intermediate panel is either two feet or four feet wide, and the other panels are correspondingly either one foot or two feet Wide. The dimensions of the side walls and roofs are chosen in units to cooperate with these dimensions so that the last intermediate panel will just reach the far margin of the wall or roof. It will then be ready to receive the finisher panel.

This third type of panel is half the width of the intermediate panel and is adapted to overlie the upper half and be supported by the flange and rib. Its lower marginal edge is provided with an inwardly extending flange which lies adjacent to the rib and is secured thereto. Its upper marginal edge is secured to the upper flange of the intermediate panel. In some cases, to strengthen the connection, the upper edge is also provided with an inwardly extending flange to be secured to the flange of the intermediate panel.

Each pair of overlapping panel portions with their ribs or flanges defines a closed rectangular box which extends longitudinally of the panels. This box provides a dead air space to serve as insulation. If desired, it can actually be filled with insulating material. The passageways can also be used to house ventilating ducts or other building accessories. The inner portions of the panels also define with the plane of the beams a series of triangular passageways which are suitable to receive electrical conduits, junction boxes, or other building accessories.

Wherever there is a connection between panels, the flanges or ribs combine to produce longitudinal beams of double width to provide an unusually strong and rigid roof structure. Since only half of each intermediate panel is exposed to the exterior and there are two panel thicknesses throughout the extent of the wall, it will be seen that this one pre-fabricated set of panels provides a complete set of sheathing and a complete set of wall exterior. In addition, it is contemplated that all of the exposed portion of each panel will be provided with a layer of weatherproof roofing material so that when the wall is assembled it will be complete with its own integral roofing, and no further work or treatment will be required.

The invention is disclosed in several modified forms having various features of strength, appearance or ease of assembly. Various other advantages and features of novelty will become apparent as the description proceeds in conjunction with the accompanying drawings, in which:

FIGURE 1 is a fragmentary perspective view of a first form of an intermediate panel of the invention;

FIIGURE 2 is a similar view of the companion starter pane FIIGURE 3 is a similar view of the companion finisher pane FIGURE 4 is a similar view of a second form of the intermediate panel;

FIGURE 5 is a similar view of the companion starter panel;

FIGURE 6 is a similar view of the companion finisher panel;

assembly, constituting a side wall, using components of the third form.

In the first form of the invention, the component A, as seen in FIGURE 1, includes a thin, narrow, elongate panel having parallel, longitudinal, marginal edges 22 and 24, and is initially rectangular in plan form. The ends, of course, may be eventually cut to any desired shape to fit into the total constructional design. This panel, as well as all of the other panels, may be of any desired material such as Masonite, plastic, or metal, but is preferably plywood of a suitable thickness for the loads to be encountered. The thickness usually ranges from three-eighths to three-quarters of an inch.

Extending inwardly, or downwardly as seen in FIG- URE 1, from the inner face 26 of the panel, at edge 22, is a longitudinal flange 28. Extending outwardly from the outer face 30 of the panel, at edge 24, is a second longitudinal flange 32. The outer free edge of this flange is formed with a longitudinal groove 34 to receive the rib or flange of a cooperating panel when a wall assembly is made up. Ribs 36 and 38 extend longitudinally of the panel in the vicinity of its longitudinal axis and extend outwardly in opposite directions. They are slightly offset laterally as shown to fit properly with the other elements of the assembly. The ribs and flanges shown in all of the figures may be of any desired material, but solid lumber is preferred.

For most present purposes it has been found that a thickness of one inch is very satisfactory for members 28, 36 and 38, with heights of two, three, or four inches for members 28 and SSdepending on the loads to be sustained. Flange 32 is normally of the same height. Flange 32 is two or three inches thick because of its groove 34, which will be one inch wide to accommodate flanges or ribs of cooperating panels. Rib 36 is designed to fit into a groove such as 34 in another panel and therefore is of lesser height. Usually it is from one third to one half of the height of flange 28, and groove 34 has a corresponding depth.

Component B, in FIGURE 2, comprises a panel 40 having inner and outer faces 42 and 44, and parallel, longitudinal, marginal edges 46 and 48 from which longitudinal flanges 50 and 52 extend in opposite directions. Panel 40 is similar in all respects to panel 20 except that it is just one half as wide. Flanges 50 and 52 correspond in all respects to flanges 28 and 32, including a groove 54 in flange 52. I a

Component C, in FIGURE 3, comprises a panel 56 having an inner face 58 and parallel, longitudinal marginal edges 60 and 62. Longitudinal flanges 64 and 66 extend inwardly from the inner face 58 at edges 60 and 62 respectively. Panel 56 is similar to panel 40, flange 64 is similar to flanges 28 and S0, and flange 66 is similar to flange 36.

The three pre-fabricated components described above may be combined and secured to suitable supporting structure to make up a wall structure of any desired dimensions, using as many intermediate panel components as necessary to cross the extent laterally of the lengths of the panels. A completed assembly, serving as a roof, is illustrated in FIGURE 10. Uprights 68. support a purlin or stringer 70 on which are mounted a plurality of beams 72 arranged at a suitable slope with their upper ends connected to ridge pole 74. The beams are normally parallel to each other and perpendicular to the longitudinal axes of the panels but this is not essential. The upper surfaces of the beams lie in a common plane.

The construction is commenced by laying component B in place as shown, with its longitudinal axis crossing the axes of the beams, in this case at right angles. The free edge of flange 50 and edge 43 of panel 40 contact the beams with the result that the panel lies in a plane at an acute angle to the common plane of the beams.

.It will be noted at this point that flange 52 overhangs edge 48 to some extent for two purposes. This allows it to directly contact the beams for better support. It is also used to establish a desired modular width for the panel. In many cases the panel is just slightly short of the proper width or has a damaged edge which must be trimmed. Therefore it is desirable to trim all the panels to a width slightly less than the desired modular width and then make up the width deficiency by the overhang of the flange. It will be seen that flange 32 overhangs panel 20 in the same way. After component B is set in place as shown and described it is secured in place, as by mailing.

A first component A is now laid in place as shown. Flange 28 is directly over flange 50 and the edge 46 of the panel 40. Rib 35 lies in groove 54 and edge 24 contacts the beams. Panel 29 now lies in a plane parallel to that of panel 40 and at the same acute angle to the plane of the beams. It is now secured in place, as by nailing. A second component A is now laid down and secured in the same way. As many of these components are used as is found necessary to complete the wall. It will be seen that groove 34 of flange 32 of each panel 20 receives rib 36 of the succeeding panel.

When the roof portion is completed as shown, using three intermediate panels or components, the finisher panel or component C is applied. Panel 56 directly overlies rib 38 and flange 32 of the last intermediate panel, and its flange 64 lies beside flange 38. Also its flange 66 lies in groove 34. It is then secured in place.

A similar construction is built up to the ridge pole from the other side in a typical roof design. Directly above the ridge pole the two constructions define a small longitudinal wedge shaped groove. This is usually small enough to be covered with a cap of roofing paper or metal flashing. If a steep pitch results in a rather large groove, it is then filled with a longitudinal wedge shaped strip of wood 76. 7

Several useful and novel features of the new construction will now be apparent. The angular relationship of the panels to the beams provides a series of triangular passageways 78, which may be blocked at selected beams by wedges as shown. These passageways are of substantial size and are adapted to receive building accessories of various kinds, such as liquid and electrical conduits. The wedges strengthen the connections between the panels and the beams.

Throughout the area of the wall there are two panels at all points, spaced from each other. Thus, by assembling these few pieces, there are provided a complete set of sheathing and a complete set of weather surfacing. The rectangular spaces 82 defined by-the panels and flanges provide dead air insulation. If desired, they may be filled with insulating material. Alternatively, one or more of them may be used to house ventilating ducts or the like.

The combination and arrangement of parts whereby various flanges and ribs lie adjacent to each other and are secured together produce compound beam or stringer assemblies as shown which are extremely strong. In effect they add up to provide beams which are Wider or higher or both, than the individual members secured to the various panels.

In the second form of the invention, component D, FIGURE 4, is quite similar to component A. It includes panel 86, flanges 88 and 90, and ribs 92 and 94 In this case, however, flange 90 is not provided with a groove and rib 92 is of the same height as flange 88 and rib 94.

Component E in FIGURE 5 is similar to component B. It includes panel 96, flange 93, and flange 100. The latter is not provided with a groove.

Component F in FIGURE 6 is similar to component C and has a panel 102, flange 104, and flange 106. Here the difference lies in the fact that flange 106 is the same height as flange 104 and is at the extreme edge of panel 102 instead of being set in like flange 66.

The three components just described are combined into that wall construction shown in FIGURE 11, also used as a roof. It can be readily seen that the components are located and secured in much the same way as those of the first embodiment. The supporting structure, as in FIGURE 10, includes uprights 108, stringer 116, beams 112, and ridge pole 114. The assembly as shown includes one E component, two D components, and one F component. The connections between them difler from the first form because rib 92 lies beside flange 101) of component E in the first overlap, rib 92 and flange 88 embrace flange 90 and rib 94 in the second overlap, and flanges 106 and 104 of component F embrace flange 9t) and rib 94 of the last component D. While the construction is basically the same, the tongue and groove connections have been eliminated.

Triangular passages 116, filled at some beams by wedges 118, are formed between the panels in the same way as in the first form. Likewise rectangular passageways 1211 are defined by the panels, flanges, and ribs. In this case the passageways are shown as housing ventilating ducts 122.

The pre-fabrication is completed by providing the exposed surfaces of the panels with weatherproof roofing material. In FIGURE 4, the layer 124 of such material overlies the right hand half of panel 86 and extends down over the outside surface of flange 88. It is also shown as extending up the side of rib 94 and over its top, although this is not essential. In FIGURE 5, layer 126 overlies the panel and the outside surface of flange 98. In this case the minimum coverage would be the flange and a portion of the panel adjacent to the edge. In FIGURE 6, layer 128 overlies the panel and the outside surface of flange 104. It need not extend down over flange 104 because a cap strip at the ridge would provide the necessary protection. The same arrangement of protective covering material is applied to the other two forms of the invention.

In the third form of the invention component G in FIGURE 7 is similar to component D and includes a panel 130, flanges 132 and 134 and ribs 136 and 13$. The panel width is a predetermined slight distance short of a predetermined modular width and this width deficiency is made up by flange 134. The latter is cut out at its lower inner corner to define a rectangular recess 140 which receives the edge of the panel. The lower outer corner has a width equal to the width deficiency so that the total assembly will have exactly the right lateral width, such as two feet or four feet.

Component H in FIGURE 8 is similar to component E and has a panel 142 and flanges 144 and 146. However, the latter is recessed in the same manner as flange 134, and flange 144 extends from both sides of panel 142 and is recessed at 14%.

Component I in FIGURE 9 is similar to component F but is simpler, having only a panel 156 and flange 152.

The assembly made up of these three components is shown in FIGURE 12 in the form of a vertical side wall. Here uprights 154 are secured at their lower ends to a base beam 156 and at their upper ends to a stringer 158 which in turn supports roof beams 160.

Component H is secured to the bottom of the framing and a series of G components are secured in echelon on and above component H. Component I is secured at the top to the last intermediate component G. In this form, it will be seen that rib 136 and flange 132 of the first intermediate component embrace flanges 146 and 144 respectively of the starter panel, thus preventing any possibility of lateral relative slippage. The other intermediate components or panels overlap in the same way as those of FIG- URE 11. The finisher panel I overlies the upper half of the last intermediate panel and its flange 152 lies in facewise engagement with rib 138.

The use of the triangular passageways to accommodate building accessories is illustrated in FIGURE 12, where passageway 162 is shown as receiving a junction box 164 and its associated electrical conduit 166.

From the above description it will be observed that the novel pre-fabricated Wall construction provides a very simple but highly satisfactory solution to many of the problems encountered in general building construction. A large wall can be made with very few parts because of their individual large size. The unique overlap arrangement and pre-application of roofing material provides sheathing and weatherboard in one operation, and in addition provides automatic insulation or provision for added insulation material or other building accessories.

It will be apparent to those skilled in the art that various changes and modifications may be made in the construction and arrangement of parts as herein disclosed without departing from the spirit of the invention, and it is intended that all such changes and modifications shall be embraced within the scope of the following claims.

I claim:

1. A multi-panel wall construction comprising: a plurality of spaced beams lying in a common plane to provide a planar basic support; a plurality of thin, narrow, elongate wall panels arranged in lateral overlapping relation with their longitudinal axes crossing the axes of said beams, and secured to said beams to constitute a complete Wall; said panels comprising a starter panel, a finisher panel, and at least one intermediate panel; said starter panel having a first flange secured to one longitudinal edge and extending inwardly substantially normal to the plane of the panel to contact the beams and support the panel at an acute angle to the plane of the beams, and having a second flange secured to its other longitudinal edge and extending outwardly from the opposite face of the panel; said intermediate panel having a longitudinal rib located in the vicinity of its longitudinal axis and extending inwardly to engage and be secured to the second flange of said starter panel, an inwardly extending flange along one longitudinal edge to engage another part of said starter panel, and an outwardly extending flange along its other longitudinal edge; said finisher panel having a longitudinal edge portion adapted to engage and be secured to the outwardly extending flange of the intermediate panel and having an inwardly extending flange at its other longitudinal edge to engage and be secured to another portion of said intermediate panel; each of said panels lying in substantially parallel planes at substantially the same acute angle to the plane of the beams.

2. A construction as claimed in claim 1; said intermediate panel having a second longitudinal rib located in the vicinity of its longitudinal axis and extending outwardly and opposite to the first mentioned rib to engage and be secured to the inwardly extending flange of the finisher panel.

3. A construction as claimed in claim 1; and at least one additional intermediate panel of substantially the same construction as the first intermediate panel, and overlapping and secured to said first intermediate panel; said finisher panel overlapping and being secured to the last one of said intermediate panels.

4. A construction as claimed in claim 1; said flanges serving to space the overlapping portions of successive panels from each other to define a series of substantially closed elongate air spaces of rectangular cross section to 7 serve as insulation and to house ventilation ducts or the like.

5. A construction as claimed in claim 1; said intermediate panels being substantially twice the width of said starter and finisher panel; approximately one half of the width of the first intermediate panel overlying all of said starter panel; and said finisher panel overlying approximately one half of the width of the last intermediate panel.

6. A construction as claimed in claim 1; the plane of said beams being inclined at a substantial angle to the horizontal, with the finisher panel being at the upper edge, and each of said panels sloping downwardly, to constitute at least a portion of a complete roof unit.

7. A construction as claimed in claim 1; the plane of said beams being substantially vertical, with the finisher panel being at the upper edge, to constitute at least a portion of a complete siding unit.

8. A multi-panel wall construction comprising: a pinrality of spaced beams lying in a common plane to provide a planar basic support; a plurality of thin, narrow, elongate wall panels arranged in lateral overlapping relation with their longitudinal axes crossing the axes of said beams, and secured to said beams to constitute a com plete wall; each of said panels lying in substantially parallel planes at substantially the same acute angle to said common plane; means spacing the overlying portions of said panels from each other to provide rectangular passageways therebetween; said panels also providing triangular passageways between their inner faces and said beams; and building accessories located in at least some of said passageways.

9. A component for use as an intermediate panel of a multi-panel wall construction, comprising: a thin, narrow, elongate wall panel having a pair of parallel 1ongitudinal, marginal edges; a pair of longitudinal ribs, each having a rectangular cross section, secured to said panel and located in the vicinity of its longitudinal axis; said ribs extending outwardly from opposite faces of said panel; a first longitudinal flange secured to one longitudinal edge of said panel and extending away from the adjacent face of said pane] in the same direction as a first one of said ribs; and a second longitudinal flange secured to the other longitudinal edge of said panel and extending away from the adjacent face of said panel in the same direction as the second one of said ribs; each of said flanges and ribs being adapted to be secured to cooperating portions of adjacent panels in an assembly to constitute a multi-panel wall construction.

10. A wall construction component as claimed in claim 9; one of said flanges having a longitudinal grooveformed in the face of its outer edge to receive the edge of a flange of an adjacent panel to obviate lateral shifting of the panels with respect to each other.

11. A wall construction component as claimed in claim 9; and a layer of weatherproof roofing material overlying and secured to one face of said panel between the rib extending from said face and the longitudinal edge and the outer surface of the flange at the longitudinal edge; the covered portions of said panel being adapted to constitute the sole portions of said panel exposed to the weather in a completed wall assembly.

12. A component for use as a starter panel of a multipanel wall construction, comprising: a thin, narrow, elongate Wall panel having a pair of parallel, longitudinal, marginal edges; a first longitudinal flange secured to a first longitudinal edge of said panel and extending away from a first face of said panel; the free edge of said flange and the second longitudinal edge of said panel being adapted to be secured to supporting members lying in a common plane to locate said panel at an acute angle to said common plane; and a second longitudinal flange secured to the second longitudinal edge of said panel and extending away from the second face of said panel in a direction opposite to said first flange; said panel and second flange being adapted to be secured to cooperating portions of an overlying panel to support the latter at the same acute angle to the common plane as said first panel; said first flange having an additional longitudinal portion extending away from the second face of said panel in the same direction as said second flange to directly engage a face portion of an overlying panel.

13. A component as claimed in claim 12; said second flange having a longitudinal groove formed in the face of its outer edge to receive the edge of a flange of an adjacent panel to obviate lateral shifting of the panels with respect to each other.

References Cited UNITED STATES PATENTS 111,605 8/1871 Cooke 52 542 117,605 8/1871 Cooke 52-542 318,872 5/1885 Crabbe 52536 688,641 12/1901 Heintz 52-536 907,824 12/ 1908 Latulip 52552 X 1,623,102 4/ 1927 Fosseen 52-552 X 1,955,464 4/1934 Tenneville 52-534 2,188,147 1/1940 Greis 52542 X 2,260,720 10/ 1941 Morthland 52542 2,358,396 9/1944 Hogan 52409 2,450,562 10/ 1948 Robinson et al 5255 3 X 2,636,226 4/ 1953 Holland 52553 3,042,193 7/ 1962 Wendt 52--420 X 3,209,503 10/ 1965 Mostoller 52-520 X FOREIGN PATENTS 18,896 12/1888 Great Britain. 903,998 3/ 1962 Great Britain.

HENRY C. SUTHERLAND, Primary Examiner.

MICHAEL O. WARNECKE, Assistant Examiner. 

1. A MULTI-PANEL WALL CONSTRUCTION COMPRISING: A PLURALITY OF SPACED BEAMS LYING IN A COMMON PLANE TO PROVIDE A PLANAR BASIC SUPPORT; A PLURALITY OF THIN, NARROW, ELONGATE WALL PANELS ARRANGED IN LATERAL OVERLAPPIN RELATION WITH THE LONGITUDINAL AXES CROSSING THE AXES OF SAID BEAMS, AND SECURED TO SAID BEAMS TO CONSTITUTE A COMPLETE WALL; SAID PANELS COMPRISING A STARTER PANEL, A FINISHER PANEL, AND AT LEAST ONE INTERMEDIATE PANEL; SAID STARTER PANEL HAVING A FIRST FLANGE SECURED TO ONE LONGITUDINAL EDGE AND EXTENDING INWARDLY SUBSTANTIALLY NORMAL TO THE PLANE OF THE PANEL TO CONTACT THE BEAMS AND SUPPORT THE PANEL AT AN ACUTE ANGLE TO THE PLANE OF THE BEAMS, AND HAVING A SECOND FLANGE SECURED TO ITS OTHER LONGITUDINAL EDGE AND EXTENDING OUTWARDLY FROM THE OPPOSITE FACE OF THE PANEL; SAID INTERMEDIATE PANEL HAVING A LONGITUDINAL RIB LOCATED IN THE VICINITY OF ITS LONGITUDINAL AXIS AND EXTENDING INWARDLY TO ENGAGE AND BE SECURED TO THE SECOND FLANGE OF SAID STARTER PANEL, AN INWARDLY EXTENDING FLANGE ALONG ONE LONGITUDINAL EDGE TO ENGAGE ANOTHER PART OF SAID STARTER PANEL, AND AN OUTWARDLY EXTENDING FLANGE ALONG ITS OTHER LONGITUDINAL EDGE; SAID FINISHER PANEL HAVING A LONGITUDINAL EDGE PORTION ADAPTED TO ENGAGE AND BE SECURED TO THE OUTWARDLY EXTENDING FLANGE OF THE INTERMEDIATE PANEL AND HAVING AN INWARDLY EXTENDING FLANGE AT ITS OTHER LONGITUDINAL EDGE TO ENGAGE AND BE SECURED TO ANOTHER PORTION OF SAID INTERMEDIATE PANEL; EACH OF SAID PANELS LYING IN SUBSTANTIALLY PARALLEL PLANES AT SUBSTANTIALLY THE SAME ACUTE ANGLE TO THE PLANE OF THE BEAMS. 